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HYDAC FILTER SYSTEMS GMBH Industriegebebiet D-66280 Sulzbach/SaarTelephone (06897) 509-01Fax (06897) 509-9046

The information in this brochure relates to the

For applications or operating conditions not described, please contact the relevant technical

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Fluid ControlContamination Handbook

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2

Hydraulic and lubrication oils Base oil += Additives*

* Example additives: – VI-improving agent – Pour-point lowering agent

– Oxidation inhibitor – Corrosion inhibitor – Antiwear – Anti-foam

API* GroupI II III IV

Oil type base oil oilPAO

Amount of saturated hydrocarbons

<90% >90% >90% 100%

Viscosity index 80–120 80–120 >120 -

Polarity High Less polarpolar

No details

Solubility of varnish High Medium Weak WeakElectrical conduc-tivity

Good Bad Low

* American Petroleum Institute (API)

Additives

lubrication oils

Base oil

3

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Code Density at 15 °C (kg/m3)

DIN 51524 or ISO 11158

H, HL, HLP, HV, HLPD 860

Fire resistant

ISO 12922

HFA/HFB 1000HFC 1090

HFDR, HFDS 1200

ISO 15380

HETG 930HEES 940HEPG 1100HEPR 890

DIN 51517

CL, CLP, CG 860

H1 lubricant “Food-grade (FG) lubricants” “Food-grade oil”

contact with foodstuffs not hazardousH2 lubricant

H3 lubricant Soluble oils for cleaning or rust protection for machines

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The higher the viscosity index of an oil, the smaller the change in viscosity in relation to the temperature.

ISO VG(DIN 51519)

Medium point viscosity (40 °C) and approx. viscosities in mm2/s at

Approximate

0 °C 40 °C 50 °C 100 °C Motor oils

Automobile transmission

SAE SAE5 47 12 (2 E) 5

10 21 (3 E) 10 815 34 15 11 5 W22 55 22 15 10 W 70 W

75 W32 88 32 21

46 137 46 30 15 W68 219 68 43 20 W 80 W

100 345 100 61 11 30150 550 150 90 15 40 85 W220 865 220 125 19 50 90320 1340 320 180 24

140460 2060 460 250 30680 3270 680 360 40

1000 5170 1000 510 50250

1500 8400 1500 740 65

40 °C 100 °C

Viscosity

Temperature

Oil A

Low viscosity index

High viscosity indexOil B

High

LowLow High

5

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Solid

Liquid

– Corundum, tinder, rust particles – Wear metals iron, copper, tin, zinc

– Fibres, rubber particles, paint particles

– Cooling water – Steam

– Oil ageing/varnish – Oil mixtures – Additive separation (dropout)

– Air – Process gases

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Cause

Solid

– Installation contamination – Ambient contamination – – Internal wear processes – Oil ageing

Liquid

– Moisture from the ambient air – – Process water/process steam – Leakage of seals – High-pressure cleaner – Chemical processes (incineration, oxidation, neutralisation)

Gel-like

– Oil ageing – Oil mixing

Gaseous

– Mixtures – Outgassing of oil

7

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Consequences

Solid

– Abrasive wear – Increased leakage – Component failure – Control inaccuracies – Blockage of control pistons –

Liquid

– Corrosion –• • Contact with surfaces• Wear

– Change in the oil properties• Creation of acidic oil degradation products• Formation of sludge• Increase in speed of oil ageing

– Cavitation damage

Gel-like

–• Increased friction and temperature• Increased bearing wear

– Malfunctions in valves•

–• Leakage

–•

–

Gaseous

– Cavitation – Oxidation – Local overheating of oil• Increase in speed of oil ageing• Control inaccuracies

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(c) (c) (c)

Solid particle contamination

ISO code

Particle count/100 ml Contamination load (ACFTD)

More than Up to and incl. [mg/l]0 1 –1 1 2 –2 2 4 –3 4 8 –4 8 16 –5 16 32 –6 32 647 64 130 –8 130 250 –9 250 500 –

10 500 1,00011 1,000 2,000 –12 2,000 4,000 –13 4,000 8,00014 8,000 16,000 –15 16,000 32,00016 32,000 64,00017 64,000 130,000 118 130,000 250,000 319 250,000 500,000 520 500,000 1,000,000 7/1021 1,000,000 2,000,000 2022 2,000,000 4,000,000 4023 4,000,000 8,000,000 8024 8,000,000 16,000,000 –25 16,000,000 32,000,000 –26 32,000,000 64,000,000 –27 64,000,000 130,000,000 –28 130,000,000 250,000,000 –

>28 250,000,0009

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Particle count per ml

Example:Larger thanLarger thanLarger than

Clea

nlin

ess

clas

s

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Max. particle concentration (particle/100 ml)

Size ISO 4402Calibration or optical counting*

Size ISO 11171, calibration or electron microscope** (c) (c) (c) (c) (c) (c)

Side code A B C D E F

Con

tam

inat

ion

clas

ses

000 195 76 14 3 1 0

00 390 152 27 5 1 0

0 780 304 54 10 2 0

1 1,560 609 109 20 4 1

2 3,120 1,220 217 39 7 1

3 6,250 2,430 432 76 13 2

4 12,500 4,860 864 152 26 4

5 25,000 9,730 1,730 306 53 8

6 50,000 19,500 3,460 612 106 16

7 100,000 38,900 6,920 1,220 212 32

8 200,000 77,900 13,900 2,450 424 64

9 400,000 156,000 27,700 4,900 848 128

10 800,000 311,000 55,400 9,800 1,700 256

11 1,600,000 623,000 111,000 19,600 3,390 512

12 3,200,000 1,250,000 222,000 39,200 6,780 1,020

* Particle sizes determined on basis of longest dimension

Solid particle contamination

11

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Max. particle concentration (particle/100 ml)

Size ISO 4402Calibration or optical counting*

Size ISO 11171, calibration or electron microscope** (c) (c) (c) (c) (c) (c)

Side code A B C D E F

Con

tam

inat

ion

clas

ses

000 195 76 14 3 1 0

00 390 152 27 5 1 0

0 780 304 54 10 2 0

1 1,560 609 109 20 4 1

2 3,120 1,220 217 39 7 1

3 6,250 2,430 432 76 13 2

4 12,500 4,860 864 152 26 4

5 25,000 9,730 1,730 306 53 8

6 50,000 19,500 3,460 612 106 16

7 100,000 38,900 6,920 1,220 212 32

8 200,000 77,900 13,900 2,450 424 64

9 400,000 156,000 27,700 4,900 848 128

10 800,000 311,000 55,400 9,800 1,700 256

11 1,600,000 623,000 111,000 19,600 3,390 512

12 3,200,000 1,250,000 222,000 39,200 6,780 1,020

The SAE cleanliness classes are based on the particle size, the particle number

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No. of particles in 100 ml sample

Particle size (µm)

5–15 15–25 25–50 50–100 >100

Cle

anlin

ess

clas

ses

00 125 22 4 1 0

0 250 44 8 2 0

1 500 89 16 3 1

2 1,000 178 32 6 1

3 2,000 356 63 11 2

4 4,000 712 126 22 4

5 8,000 1425 253 45 8

6 16,000 1,850 506 90 16

7 32,000 5,700 1,012 180 32

8 64,000 11,600 2,025 360 64

9 128,000 22,800 4,050 720 128

10 256,000 45,600 8,100 1,440 256

11 512,000 91,200 16,200 2,880 512

12 1,024,000 182,400 32,400 5,760 1,024

Like ISO 4406 and SAE AS 4059, NAS 1638 describes particle concentrations in

In contrast to ISO 4406, certain particle size ranges are counted in NAS 1638 and

Solid particle contamination

13

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ISO 4406 Class 14/12/9SAE AS 4059 Class 4 NAS 1638 Class 3

ISO 4406 Class 15/13/10SAE AS 4059 Class 5NAS 1638 Class 4

Solid particle contamination

Oil volume: 100 ml

15

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ISO 4406 Class 16/14/11SAE AS 4059 Class 6NAS 1638 Class 5

ISO 4406 Class 17/15/12SAE AS 4059 Class 7NAS 1638 Class 6

Oil volume: 100 ml

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ISO 4406 Class 18/16/13SAE AS 4059 Class 8NAS 1638 Class 7

ISO 4406 Class 19/17/14SAE AS 4059 Class 9NAS 1638 Class 8

Solid particle contamination

Oil volume: 100 ml

17

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ISO 4406 Class 20/18/15SAE AS 4059 Class 10NAS 1638 Class 9

ISO 4406 Class 21/19/16SAE AS 4059 Class 11NAS 1638 Class 10

Oil volume: 100 ml

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ISO 4406 Class 22/20/17 SAE AS 4059 Class 12 NAS 1638 Class 11

ISO 4406 Class 23/21/18 SAE AS 4059 Class 13 NAS 1638 Class 12

Solid particle contamination

Oil volume: 100 ml

19

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Predominantly rust,additives (white particles)

Effect: – Strong oil ageing – Malfunctions in pumps, valves –

Oil degradation products

Effect: – Filter blockage –

Effect: – Malfunctions in pumps, valves – Seal wear – Leakage – Oil ageing

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Particles/chips, bronze, brass or copper

Effect: – Malfunctions in pumps, valves – Oil ageing – Leakage – Seal wear

Gel-like residue

Effect: – Filter blockage –

Silicates resulting from absent or

Effect: – Strong wear on components – Malfunctions in pumps, valves – Seal wear

Solid particle contamination

21

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Paint particles (red/brown)Plastic particles (blue)

Effect: – Malfunctions in pumps, valves – Seal wear

Fibres resulting from initial contamination, open tank, cleaning cloths etc.

Effect: – – Leakage of poppet valves

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3) Valid for the average diameter range

Low/medium pressure<140 bar

(Moderate conditions)

High pressure140 to 200 bar

(Low/medium underbad conditions1)

Very high pressure>200 bar

(High pressure under badconditions1)

ISO 4406Target cleanliness class

ISO 4406Target cleanliness class

ISO 4406Target cleanliness

class

Pumps/motorsGear or vane 20/18/15 20 19/17/14 10 18/16/13 5Piston 19/17/14 10 18/16/13 5 17/15/12 3Variable vane 18/16/13 5 17/15/12 3 not required not requiredVariable piston 18/16/13 5 17/15/12 3 16/14/11 3 2)

Drives20/18/15 20 19/17/14 10 18/16/13 516/15/12 3 16/14/11 3 2) 15/13/10 3 2)

Test benches 15/13/10 3 2) 15/13/10 3 2) 15/13/10 3 2)

ValvesNon-return valve 20/18/15 20 20/18/15 20 19/17/14 10Directional valve 20/18/15 20 19/17/14 10 18/16/13 5

20/18/15 20 19/17/14 10 18/16/13 5Poppet valve 19/17/14 10 18/16/13 5 17/15/12 3Proportional valve 17/15/12 3 17/15/12 3 16/14/11 3 2)

Servo valve 16/14/12 3 2) 16/14/11 3 2) 15/13/10 3 2)

BearingPlain bearing 3) 18/15/12 10 not required not required not required not requiredGears 3) 17/15/12 10 not required not required not required not requiredBall bearing 3) 15/13/10 3 2) not required not required not required not requiredRoller bearing 3) 16/14/11 5 not required not required not required not required

ISO 4406 target cleanliness class Filtration rating µmTank 18/16/13Injection system 12/10/8

Solid particle contamination

23

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Low/medium pressure<140 bar

(Moderate conditions)

High pressure140 to 200 bar

(Low/medium underbad conditions1)

Very high pressure>200 bar

(High pressure under badconditions1)

ISO 4406Target cleanliness class

ISO 4406Target cleanliness class

ISO 4406Target cleanliness

class

Pumps/motorsGear or vane 20/18/15 20 19/17/14 10 18/16/13 5Piston 19/17/14 10 18/16/13 5 17/15/12 3Variable vane 18/16/13 5 17/15/12 3 not required not requiredVariable piston 18/16/13 5 17/15/12 3 16/14/11 3 2)

Drives20/18/15 20 19/17/14 10 18/16/13 516/15/12 3 16/14/11 3 2) 15/13/10 3 2)

Test benches 15/13/10 3 2) 15/13/10 3 2) 15/13/10 3 2)

ValvesNon-return valve 20/18/15 20 20/18/15 20 19/17/14 10Directional valve 20/18/15 20 19/17/14 10 18/16/13 5

20/18/15 20 19/17/14 10 18/16/13 5Poppet valve 19/17/14 10 18/16/13 5 17/15/12 3Proportional valve 17/15/12 3 17/15/12 3 16/14/11 3 2)

Servo valve 16/14/12 3 2) 16/14/11 3 2) 15/13/10 3 2)

BearingPlain bearing 3) 18/15/12 10 not required not required not required not requiredGears 3) 17/15/12 10 not required not required not required not requiredBall bearing 3) 15/13/10 3 2) not required not required not required not requiredRoller bearing 3) 16/14/11 5 not required not required not required not required

ISO 4406 target cleanliness class Filtration rating µmTank 18/16/13Injection system 12/10/8

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Saturation point

Liquid contamination

Dissolved waterBelow the saturation point

– Water is present in the oil in dissolved form – like the water

– All water molecules are deposited on polar oil components

Free waterAbove the saturation point

– Water is present as an emulsion (similar to fog), with ultra-

–

Temperature [°C]

1200

1000

800

600

400

200

050403020100-10-20

Free and

Dissolved water

Wat

er c

onte

nt [p

pm]

25

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Water content [%]

Rel

ativ

e lif

e ex

pect

ancy

of

rolle

r bea

rings

Wat

er s

atur

atio

n [p

pm]

Temperature [°C]

Diesel

Group V

Group IV

Group I, II, III

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Gel-like contamination (oil degradation product/varnish)

Laboratory analyses – varnish: – MPC (membrane patch colorimetry) based on ASTM D7843-12

– Particle measurement at 20°C and 80°C based on ISO 11500

Particle count in an oil sample

Particle differenceAt 80 °CAt 22 °C

Par

ticle

cou

nt p

er 1

ml

27

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Typical images of deposits in a steam turbine

Coupling sleeve

Gear teeth

Valve piston with deposits

Oil samples at room temperature with slight clouding

Filter membrane before and after varnish separation

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Gaseous contamination

Relationship between pressure and temperature

At 20 °C and 1 bar(atmospheric pressure)

in 100 litres oil,

With pressure reduction to

in 100 litres oil,

2 litres of air released!

80 °C

20 °C

0,50 1,0 1,5 2,0 2,50,8

20

10

8

Gas bubble

Oil carbon/varnish

Range Pressure TemperatureA 1 bar 38 °CF 69 bar 766 °CH 138 bar 994 °CI 207 bar 1140 °C

29

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Limit values of typical standard for fresh oil

ISO VG/type 32 46 68 100 (150) (>320)

Turbine oil DIN 51515, ISO 8068 5 5 6 x x x

DIN 51524/2, ISO 11158 5 10 13 21 32 x

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Contamination type Typical separation method/oil conditioning devices

Solid

ContaminationSensor CS 1000

Metallic ContaminationSensor MCS 1000

ContaminationSensor Module CSM-E

FCU 1315

MFU

OffLine Filter OLF 5

OffLine Filter BiDirectional OLFBD

Liquid

AquaSensorAS 1000 & AS 3000

FluidAqua Mobil FAM

OffLine Separator OLS

MFU

ContaminationSensor Module CSM-E

FCU 1315

Coalescer Diesel LVH-CD

AquamicronAM

Gel-like

VEU-F IXU

Gaseous

FluidAqua Mobil FAM

OXiStop OXS

31

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Contamination type Typical separation method/oil conditioning devices

Solid

ContaminationSensor CS 1000

Metallic ContaminationSensor MCS 1000

ContaminationSensor Module CSM-E

FCU 1315

MFU

OffLine Filter OLF 5

OffLine Filter BiDirectional OLFBD

Liquid

AquaSensorAS 1000 & AS 3000

FluidAqua Mobil FAM

OffLine Separator OLS

MFU

ContaminationSensor Module CSM-E

FCU 1315

Coalescer Diesel LVH-CD

AquamicronAM

Gel-like

VEU-F IXU

Gaseous

FluidAqua Mobil FAM

OXiStop OXS

Filter element

Vacuum evaporation Coalescence Superabsorber

Vacuum drying

Ion exchanger